Monkman33's Long and Slow "Process"
 

Hey all. Some of you know me, some of you don't. I've had my FD for 7 years now, and it has never ran. Yeah, lesson learned: Don't buy a project car when you're 22 and live in an apartment. Now I am 29 and have my own house, so progress can happen from time to time.... barring getting laid off for 6 months at a time. However, members on the forums were more than willing to purchase some items from me that helped me stay afloat and keep moving forward now that I am back to work.

Over the years, my goals have been pretty liquid. But I have nailed things down to one ultimate goal:

To build my vision of an FD for today while maintaining the spirit of the original design.

So, I will post up 6 years worth of progress. Sounds like a lot... but it's really not. I will probably condense it a bit since I have to upload 1 at a time. ;-)


Here is the FD when it got delivered to my family's place. (Remember: Dumb 22 year old in an apartment, burdening his family with his own poor choices)

http://rotarycarclub.com/rotary_foru...1&d=1373135510

http://rotarycarclub.com/rotary_foru...1&d=1373135510

http://rotarycarclub.com/rotary_foru...1&d=1373135510

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http://rotarycarclub.com/rotary_foru...1&d=1373135510

Here are some pics of the teardown. I had actually bought a brand new engine from Malloy originally. However, i sold that to pay for a wedding... (that didn't last). Another lesson learned.

http://rotarycarclub.com/rotary_foru...1&d=1373135890

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Here are some pics of stripping the engine down. Originally, I was just going to put it all back together as it was. Then I got carried away.

It was insane how much debris was found in the turbos themselves later on. I just never got a good picture of that.

http://rotarycarclub.com/rotary_foru...1&d=1373136155

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And here is her second home. She then went to a garage at an apartment complex. Then to a storage unit. Then to the garage she is in now.

Transmission
 

Transmission:
This thing came in a bunch of boxes inside the car on delivery day. These pics span 7 years.

http://rotarycarclub.com/rotary_foru...1&d=1373136581

Also, how long will Neo Synthetic stay good for? I may have a 7 year old gallon of it...

http://rotarycarclub.com/rotary_foru...1&d=1373136581

http://rotarycarclub.com/rotary_foru...1&d=1373136581

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Yeah, I know, I was totally going ghetto on this. But it was 7 years ago, so cut me a little slack.

Transmission Cont.
 

So I got the main stack of 1st through 4th installed. But after 6 years, I didn't know where I was at in the process and I didn't have the space in my garage to finish it up. So I cheated and took it to a shop to finish it up. He said the good news is that I had assembled everything properly, so it was an easy gig for him top close it up. He charged me a very fair number and sent me on my way. After all, he said I had already done the hard part.

http://rotarycarclub.com/rotary_foru...1&d=1373137009

http://rotarycarclub.com/rotary_foru...1&d=1373137009

Dropped it off at American Transmission at this point:

http://rotarycarclub.com/rotary_foru...1&d=1373137009

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And here it is. All done and in my packed garage.

http://rotarycarclub.com/rotary_foru...1&d=1373137009

Here is my garage today. (well, not today, there is a pile of carpets in the work area along with a dash at the current moment)

http://rotarycarclub.com/rotary_foru...1&d=1373137470

http://rotarycarclub.com/rotary_foru...1&d=1373137470

The next batch of pictures of the engine assembly is from IRP.

Engine specs:
9.7:1 induction hardened rotors from rotaryengine.com
Rotors have been lightened and balanced by rotaryengine.com
water jacket mods, oil passage mods, porting and assembly by IRP

http://rotarycarclub.com/rotary_foru...1&d=1373137470

http://rotarycarclub.com/rotary_foru...1&d=1373137470

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http://rotarycarclub.com/rotary_foru...1&d=1373138643

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http://rotarycarclub.com/rotary_foru...1&d=1373138763

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http://rotarycarclub.com/rotary_foru...1&d=1373139127

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http://rotarycarclub.com/rotary_foru...1&d=1373139127


It's a good thing that Rich sent it out with a scrap oil pan on it. the pallet broke and damaged the pan even more to where I had to bend it out of the way of the pan bolts.
http://rotarycarclub.com/rotary_foru...1&d=1373139127

Installed the Xcessive oil pan, but I might be pulling it off to add some baffling.

http://rotarycarclub.com/rotary_foru...1&d=1373220249

Noltec Motor Mounts - these may be up for sale soon, as there is something else in the works.

http://rotarycarclub.com/rotary_foru...1&d=1373220249

Zeeshan Oil Filler Neck and ReSpeed oil filter pedestal (pedestal may get replaced with something else too)

http://rotarycarclub.com/rotary_foru...1&d=1373220249

The RA OMP Adapter: It didn't fit so I had to ream one of the mountingholes out a bit.

http://rotarycarclub.com/rotary_foru...1&d=1373220249

http://rotarycarclub.com/rotary_foru...1&d=1373220249

FFE 60-2 Trigger Wheel:

http://rotarycarclub.com/rotary_foru...1&d=1373220553

FFE Primary Fuel Rail: I ended up using the riser piece to tap in the injector adapter pieces. worked extremely well. Will probably need a slide hammer/pilot bearing removal tool to get them out) And not a good picture of them, but those are ID1000's that I purchased from FFE as well.

http://rotarycarclub.com/rotary_foru...1&d=1373220553

http://rotarycarclub.com/rotary_foru...1&d=1373220553

http://rotarycarclub.com/rotary_foru...1&d=1373220553

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I went to test fit the exhaust manifold/turbos/lim and found an exhaust stud that haad been damaged. probably when the pallet broke. It was just spinning/pulling out of the housing when I tightened it down to 20ft/lbs.

So, here is a down and dirty process of fixing that problem. I was a bit nervous, because if I messed this up, my only next option was a Big-Sert. if I messed that up, it was replacing a housing time. Not my idea of fun... nor cheap. And just so everyone knows, this was my first time ever doing a helicoil.

http://rotarycarclub.com/rotary_foru...1&d=1373220874

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these are the EGT thermocouples I am using the the sensor connection.

http://rotarycarclub.com/rotary_foru...1&d=1373221806

Here is the reference picture I used to plan out my locations: I forget the source (sorry, my bad)

http://rotarycarclub.com/rotary_foru...1&d=1373221806

And getting it all done:

http://rotarycarclub.com/rotary_foru...1&d=1373221806

http://rotarycarclub.com/rotary_foru...1&d=1373221806

http://rotarycarclub.com/rotary_foru...1&d=1373221806

Love the car. Good work, should be a lot of fun when you get it running again.

http://rotarycarclub.com/rotary_foru...1&d=1373222056

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http://rotarycarclub.com/rotary_foru...1&d=1373222056

I finally got back to work a little bit ago and was able to start purchasing parts for the FD again so here is the new pile of goodies:
ACT HD Pressure Plate w/ SS Disk. ACT Pro-Lite Flywheel. Innovate TC4 and LC1. Adaptronic e1280s.

http://rotarycarclub.com/rotary_foru...1&d=1373222247

http://rotarycarclub.com/rotary_foru...1&d=1373222247

flywheel installed:

http://rotarycarclub.com/rotary_foru...1&d=1373222247

IRP informed me that they installed a new pilot bearing, but I didn't do a good job of keeping it from getting dirty and there was some noticeable dirt/grime in it from sitting near the open end of my garage on a couple windy days. I just didn't think to cover that spot with tape. So I opted to pop in a new one and seal it up this time.

http://rotarycarclub.com/rotary_foru...1&d=1373222247

http://rotarycarclub.com/rotary_foru...1&d=1373222247

http://rotarycarclub.com/rotary_foru...1&d=1373222678

http://rotarycarclub.com/rotary_foru...1&d=1373222678

Clutch disk and pressure plate installed. This is absolutely a CAKE job when the engine is on a stand and you can have it facing upwards. WAY easier than underneath the car. But I guess that is true for almost any engine work. I think I just noticed it more on the pressure plate/clutch job specifically.

http://rotarycarclub.com/rotary_foru...1&d=1373222678

Got some more misc pieces for the fuel system from FFE.

http://rotarycarclub.com/rotary_foru...1&d=1373222678

Here is the FFE 4 injector rail for the excessive manifold in its development:

http://rotarycarclub.com/rotary_foru...1&d=1373222678

FFE Rails:

http://rotarycarclub.com/rotary_foru...1&d=1373223023

Adaptronic e1280s with long flying lead harness:

http://rotarycarclub.com/rotary_foru...1&d=1373223023

Innovate TC4 and LC1:

http://rotarycarclub.com/rotary_foru...1&d=1373223023

And for the current progress on the interior:

Got the seats and bins removed:

http://rotarycarclub.com/rotary_foru...1&d=1373223023

Dash removed:

http://rotarycarclub.com/rotary_foru...1&d=1373223023

http://rotarycarclub.com/rotary_foru...1&d=1373223225

Had to remove the AC to get the evaporator and heater core out. I'm not cutting any corners on this carpet install. I don't want to run the risk of any sagging or non-oem level of quality. Plus, it will be a good time to refurbish the foam seals in all of these components.

http://rotarycarclub.com/rotary_foru...1&d=1373223225

Everything out:

http://rotarycarclub.com/rotary_foru...1&d=1373223225

This is the Tfent Carpet that will be going in. I have had this in its box for years. I am very lucky that rodents didn't get to it at some point, especially considering it spent a year or more in a storage unit.

http://rotarycarclub.com/rotary_foru...1&d=1373223225

My stepfather and family wanted to help out with the car in some way and when I told him I was going to order some black leather seat skins, he said he would rather take them down to a local guy here in the Tri-Cities to get them redone for me. He had his truck interior done by this shop and said they wouldn't disappoint. I was beyond grateful for the financial help and the fact that they are supportive in this build as they know how long I have been researching and working on this car.

Seats before: (not terrible, but not good either)

http://rotarycarclub.com/rotary_foru...1&d=1373223502

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Here is the embroidery on the headrests: This was done by Short Dog Embroidery, another local small business here in Tri-Cities:

http://rotarycarclub.com/rotary_foru...1&d=1373223759

http://rotarycarclub.com/rotary_foru...1&d=1373223759

And here is the shop the seats went to: Antonio is the owner. He used to work for Bud who started the shop and then bought the business from him when Bud retired. His son is the one who did my seats. I even dropped off the new seatbelt straps for the seats and they installed those too.

http://rotarycarclub.com/rotary_foru...1&d=1373223759

And here are the seats!

http://rotarycarclub.com/rotary_foru...1&d=1373224070

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http://rotarycarclub.com/rotary_foru...1&d=1373224070

RedlineGoods did these up to match: Console cover, shift boot and E brake boot:

http://rotarycarclub.com/rotary_foru...1&d=1373224070

That's it for now. Once I get more progress completed I will post up some more. TTT, I'm hoping I can still pick your brain for the bulkhead connector advice at the firewall. :-)

The seats turned out really nice! It's difficult to find a good upholstery shop in my area... be grateful you had those guys!

Looking forward to the rest of the build.

Thanks! I am waiting on my turbos to come back. They are currently at BNR to get the upgraded compressor wheel, and then they are going to Turblown to do their abraidable seal coating on the inside of the compressors (similar to the concept in the 99 spec). Bryan at BNR has told me that this will limit the peak power as that extra space helps the compressor make a bit more top end flow, however, the tighter clearance should help spool and make a more efficient midrange powerband. Perfect! That is exactly what I am looking for.

Once the turbos are back, I can test fit the whole setup with the xcessive lim and ra omp adapter with the mikuni omp. Lots of "maybe it'll fit" going on here at the moment.

So, after sitting in its packaging for years, I sent my RedLineGoods center console cover back to them to re-stitch it with silver thread to match the seats. And decided that it would be a good time to do the install.

Quick overview:
If you can get someone to help you... do it. An extra set of hands was a definite must!
Dont let leather sit for years and then expect it to unfold without some residual markings left.
Be patient. My lines didn't end up exactly how I wanted them because I got into a hurry by the end of the second night. (technically third)
I now know why I would pay a professional shop to do this.


The first night was removing the stock covering... which was in perfect shape, and I am an idiot in hindsight. I should have just bought one in crappy shape and sold this one for a profit. But, you live and learn. (probably not in my case) I left the stock foam layer to give the leather a bit of the "cushy" feel. Then I stretched the leather so both holes lined up and put the grommets back in to hold it in place. I left it like this overnight to allow the leather to settle out a bit.

http://rotarycarclub.com/rotary_foru...1&d=1374428034

Here it is stripped down. Still kicking my self for tearing apart a mint OEM one.

http://rotarycarclub.com/rotary_foru...1&d=1374428034

Leather stretched over and left to sit for a night.

http://rotarycarclub.com/rotary_foru...1&d=1374428034

The stuff I used to stick the new one on. Its pretty good stuff. Paint it on, let it dry, sticks to itself like crazy! It takes multiple layers on the backside of the leather to make it stick right. But once it's on... not chance it's coming off.

http://rotarycarclub.com/rotary_foru...1&d=1374428034

left the grommets in and just rolled the leather back to make sure it started exactly where I wanted it to.

http://rotarycarclub.com/rotary_foru...1&d=1374428034

One side done.

http://rotarycarclub.com/rotary_foru...1&d=1374428297

and working my way down a side.

http://rotarycarclub.com/rotary_foru...1&d=1374428297

Finishing up the driver's side.

http://rotarycarclub.com/rotary_foru...1&d=1374428297

Driver's side done.

http://rotarycarclub.com/rotary_foru...1&d=1374428297

Factory Grommet re-used.

http://rotarycarclub.com/rotary_foru...1&d=1374428297

Inside edges

http://rotarycarclub.com/rotary_foru...1&d=1374428549

Starting on the passenger side. This part is stressful. You have to keep tension on the leather for the holes to match up, and then you have to lay it down without out leaving bubbles, etc. Extra person = way easier.

http://rotarycarclub.com/rotary_foru...1&d=1374428549

Inside edges

http://rotarycarclub.com/rotary_foru...1&d=1374428549

Inside Progress.

http://rotarycarclub.com/rotary_foru...1&d=1374428549

This is where I hurried a little bit... or just wasn't paying attention. Honestly.. I just wasn't paying attention. The stitching lines got a bit too far up and inside. I wanted one line to line up with the middle of the e-brake boot and the other to go right below the boot hole.

http://rotarycarclub.com/rotary_foru...1&d=1374428549

Here is the finished product. There was no way I was going to be able to peel up the leather after it was stuck down... I would destroy the foam underneath. And every imperfection in that foam WILL show through the leather. You can see in this picture how the stick rolls over in the e-brake cut-out. I am hoping it looks good once it is all back together, or I will be getting another one and doing it all over. Luckily, that can be done after the whole project is done, as it will not affect the drivability or finished status of the vehicle. And I don't have to remove the whole interior to get to this piece. It's actually one of the easier parts to remove.

http://rotarycarclub.com/rotary_foru...1&d=1374428734

http://rotarycarclub.com/rotary_foru...1&d=1374428734

I am impressed with the RedLineGoods console cover, the material quality, and the overall product for the price. If I hadn't already bought all three main items they off for the FD, I would definitely have made further purchases based on this item. (ie shift and e-brake boots)